Instruction Manual ULTRA LOW NOX RESIDENTIAL GAS WATER HEATERS NOT FOR USE IN MANUFACTURED (MOBILE) HOMES LOW LEAD CONTENT • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE............................3 Fresh Air Openings For Confined Spaces............................. 13 GENERAL SAFETY INFORMATION.........................................4 Outdoor Air Through Two Openings......................................13 Abbreviations Used.................................................................5 Outdoor Air Through Two Horizontal Ducts........................... 14 Qualified Installer or Service Agency..................
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION 4
INTRODUCTION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. ABBREVIATIONS USED This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings throughout the manual that you must read and be aware of.
INSTALLATION CONSIDERATIONS GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H Vent Pipe Drafthood Anode Hot Water Outlet Outlet Insulation Gas Supply Manual Gas Shut-off Valve I J K L M N O P Ground Joint Union Sediment Trap Inner Door Outer door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Q R S T U V W X Temperature-Pressure Relief Valve Rating Plate Flue Baffle(s) Gas Control Valve/Thermostat Drain Valve Pilot and Main Burner Flue Metal Drain Pan (T) GAS CONTROL VALVE/
THERMOMETERS (NOT SUPPLIED) the structure. For this reason, it is not advisable to install water heater in an attic or upper floor. When such locations cannot be avoided, a suitable metal drain pan should be installed under the water heater. Metal Drain pans are available at your local hardware store. Such a metal drain pan must have a minimum length and width of at least 2” (51 mm) greater than water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.
CLEARANCES used in the same room or area containing a gas water heater or other open flame or spark producing appliance. NOTE: Flammable vapors may be drawn by air currents from other areas of the structure to the appliance. Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 4” (102 mm) for 100 gallon unit and 5” (127 mm) for 75 gallon unit at the front, and 6” (153 mm) from the vent pipe. Clearance from the top of the jacket is 12” (305 mm).
INSULATION BLANKETS CIRCULATION PUMPS A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater. See Water Piping Diagrams in this manual for installation location of circulating pumps. Breathing Hazard - Carbon Monoxide Gas See the Circulation Pump Wiring Diagrams below for electrical hookup information. Install in accordance with the current edition of the National Electrical Code, NFPA 70.
INSTALLATION REQUIREMENTS MIXING VALVES GAS SUPPLY SYSTEMS Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate.
WATER PIPING WATER (POTABLE) HEATING AND SPACE HEATING This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.
NOTE: In addition to the factory installed Temperature-Pressure Relief Valve on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature-Pressure Relief Valve for remote storage tanks.
OUTDOOR AIR THROUGH TWO OPENINGS amount of combustion air can result in a fire or explosion and cause property damage, serious bodily injury or death. UNCONFINED SPACE An Unconfined Space is one whose volume is not less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 11. Each duct opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.
If the water heater is being installed as a replacement for an existing heater in pre-existing venting, a thorough inspection of existing venting system must be performed prior to any installation work. The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1/4 inch per linear foot (21 mm per meter). See Figure 14.
GAS PIPING TABLE 4. LENGTH IN METERS Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. Size the main gas line in accordance with Table 3. The figures shown are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which is considered normal for low pressure systems. Note: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop.
SEDIMENT TRAPS Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping. The sediment trap must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push down or turn the gas electric spark gas ignition system.
TEMPERATURE REGULATION Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 30°F (16.7°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards. Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower.
Because of the suddenness and amount of water, condensation water may be diagnosed as a “tank leak”. After the water in the tank warms up (about 1-2 hours), the condition should disappear. Smelly water may be eliminated or reduced in some water heater models by replacing the anode(s) with one of less active material, and then chlorinating the water heater tank and all hot water lines.
PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION sooting can result in a fire causing death, serious injury, or property damage. Flame Characteristics Correct Flame Red/Orange FIGURE 19. Natural Gas (Low Nox) Burner Door Assembly Use brush on this surface Burner Pilot Assembly At least once a year a visual inspection should be made of the venting system. You should look for: 1. Obstructions which could cause improper venting. The combustion and ventilation air flow must not be obstructed. 2.
TEMPERATURE-PRESSURE RELIEF VALVE TEST INSTALLED IN SUITABLE AREA: To insure sufficient ventilation and combustion air supply, proper clearances from the water heater must be maintained. See Facts to Consider About The Location section. Combustible materials such as clothing, cleaning materials, or flammable liquids, etc. must not be placed against or adjacent to the water heater which can cause a fire. Burn hazard. Hot water discharge.
DRAINING AND FLUSHING TO FLUSH THE WATER HEATER STORAGE TANK: 1. Ensure the cold water inlet valve is open. 2. Open a nearby hot water faucet and let the water run until the water is no longer hot. Then close the hot water faucet. 3. Connect a hose to the drain valve and terminate it to an adequate drain. 4. Ensure the drain hose is secured before and during the entire flushing procedure. Flushing is performed with system water pressure applied to the water heater. 5.
REPLACEMENT PARTS REPLACING PARTS Natural Gas Burner (Ultra Low Nox) Check the burner screen to see if it is dirty or clogged. The burner screen may be cleaned with a soft paint brush. Do not use a wire brush or any tool that might damage the burner screen. IMPORTANT: The following maintenance procedures should be performed by a qualified person. Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly.
Replacing the Burner Door Assembly Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button, electrode and wire. The pilot is ignited by an electric spark generated when the igniter button is pressed. The electrode should be centered between the pilot and thermocouple (Figure 23). Use only factory authorized piozoelectric igniter parts for replacement. WARNING Testing the Igniter System Turn off the gas to the water heater at the manual gas shut-off valve.
Removing and Replacing the Gas Control Valve/ Thermostat: 6. IMPORTANT: The gas control valve/thermostat is a standard valve with a right hand thread thermocouple. Use only factory authorized replacement parts. To remove the gas control valve/thermostat, thread a correctly sized pipe into the the inlet and use it to turn the gas valve (counterclockwise). Do not use a pipe wrench or equivalent to grip body. Damage may result causing leaks.
LEAKAGE CHECKPOINTS Read this manual first. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water. Never use this water heater unless it is completely filled with water to prevent damage to the tank. Water must flow from the hot water faucet before turning “ON” gas to the water heater. A. Water at the draft hood is water vapor which has condensed out of the combustion products.
REPAIR PARTS Key No. Part Description 1 Pipe Nipple 2 Burner Tube 3 Burner Head 4 Thermocouple 5 Pilot 6 Draft Hood 7 Inlet Tube 8 Flue Baffle Assembly 9 Anode Rod 10 Outer Door 11 Gas Control Valve/Thermostat 12 T & P Relief Valve 13 Drain Valve 14 Pilot Tube 15 Orifices *16 Metal Drain Pan *17 Instruction Manual 8 9 7 12 11 * Not Shown.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent. Problem WATER LEAKS LEAKING T&P VALVE SMELLY WATER PILOT WILL NOT LIGHT Cause Improperly sealed, hot or cold supply connection, relief valve, or thermostat threads. Leakage from water lines. Condensation of flue products. Thermal expansion in closed water system. Solution Tighten thread connections. High sulfate or mineral content in water supply. Inspect water lines and connections.
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ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953 COPYRIGHT © 2015, INC. ALL RIGHTS RESERVED.
